Battery Pack Structural Support Assembly for Vibration and Impact Loads
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery pack assemblies in electrified vehicles experience deformation and failure due to vibrations and impact loads during driving, which can lead to relative movement and damage of cooling plate components.
Innovation Solution
A structural frame support assembly using extruded aluminum members coated with structural glue is integrated into the battery pack, providing support between the cooling plate and other components to inhibit relative movement and absorb vibrations uniformly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional battery pack assemblies are used without additional structural support, then the device complexity is low, but the reliability deteriorates due to deformation from vibrations and impact loads
Solution Approach 1:
The structural support assembly is divided into multiple discrete beam elements (front beam, rear beam, side beams, and middle beams) that are strategically positioned to provide targeted support to the cooling plate and battery pack components, allowing the complex support function to be achieved through modular, segmented structure
Solution Approach 2:
The patent combines extruded aluminum beam members with structural glue to create a composite support system that leverages the strength and rigidity of aluminum extrusions along with the bonding and vibration-damping properties of structural adhesive, enhancing overall reliability through material composition
2Strength
If structural glue is used to connect support members to cooling plate and bottom plate, then the anti-impact capability is improved, but the manufacturing precision requirement increases
Solution Approach 1:
The structural glue is applied locally at specific interfaces between support members and adjacent components (cooling plate and bottom plate) rather than throughout the entire structure, concentrating the bonding function where needed while reducing overall manufacturing complexity
Solution Approach 2:
The structural glue serves as an intermediary material between the rigid extruded aluminum support members and the cooling plate/bottom plate, providing both mechanical bonding and vibration dampening that enhances impact resistance while accommodating minor manufacturing tolerances
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively enhances the anti-impact and vibration absorption capabilities of the battery pack, minimizing deformation and extending the lifespan of the components by distributing and mitigating vibrations and impacts more uniformly.
Implementation Method 1
structural glue is disposed between the front support member and the cooling plate... first structural glue is configured to inhibit relative movement between the front support member and the cooling plate
Data Source
AI summary
A battery pack assembly for an electrified vehicle includes a top cover, a cooling plate, a bottom plate and a main body assembly. The main body assembly comprises a structural frame support assembly having a front beam, a rear beam, a first side beam and a second side beam. A middle beam provides structural support to the cooling plate. A front support member is disposed at least partially between the cooling plate and the bottom plate. A rear support member is disposed at least partially between the cooling plate and the bottom plate. First structural glue is disposed between the front support member and the cooling plate.